Fork Contact Connector for Soldering Fine Stranded Conductors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Connecting high-frequency strands with a large number of small-diameter individual conductors to a conductor substrate is challenging due to handling difficulties and risk of conductor dissolution in solder, especially when long soldering times are required.
Innovation Solution
A fork-like contact-making element with spaced tines and a fanned-out conductor end allows for easy and stable electrical connection, with the conductor end being held between the tines for secure soldering or welding, enhancing the contact surface and accessibility to solder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a large number of small-diameter individual conductors are combined into a stranded bundle, then losses due to heating are reduced, but handling and soldering become difficult
Solution Approach 1:
The contact-making element is segmented into multiple tines that can be spread apart to create an intermediate space, allowing the stranded conductor bundle to be inserted and individually contacted by each tine, facilitating both handling and soldering while maintaining the energy efficiency of the stranded configuration
Solution Approach 2:
The intermediate space between the tines acts as an intermediary structure that receives and organizes the stranded conductor bundle, enabling the soldering process to access individual conductors within the bundle without requiring manual handling of the entire stranded assembly
2Reliability
If long soldering times are used to achieve desired contact, then connection reliability improves, but conductor dissolution in solder increases
Solution Approach 1:
The conductor end is preliminarily prepared by fanning out the individual conductors within the intermediate space before soldering begins, creating optimal contact geometry that enables reliable electrical connection and mechanical bonding with reduced soldering time, thereby preventing conductor dissolution
Solution Approach 2:
The tines are designed with specific local geometries including barbs and flattened contact surfaces at their ends, creating localized areas of high contact quality and mechanical interlocking that ensure reliable connections with minimal soldering exposure, reducing the risk of conductor dissolution
3Area of stationary object
If individual conductors are fanned out at the end, then contact surface and solder accessibility are improved, but conductor structure complexity increases
Solution Approach 1:
The fanned-out individual conductors are nested within the intermediate space defined by the tines, with each conductor positioned in a specific spatial relationship to the tines and to each other, creating an organized complex structure that maximizes contact surface area while maintaining manufacturability through the defined geometric constraints of the intermediate space
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the connection process, ensures a stable and reliable electrical contact, and prevents conductor dissolution by providing a secure and enlarged contact area for soldering or welding, even with complex strand configurations.
Implementation Method 1
the end of the electrical conductor being arranged in the intermediate space between the first tine and the second tine and being electrically conductively connected to the first tine and/or the second tine
Implementation Method 2
The contact-making element can then be soldered, for example using a foot formed on the contact-making element, to a conductor substrate, for example a printed circuit board
Implementation Method 3
The end of the electrical conductor is soldered or welded to the electrically conductive contact-making element
Data Source
AI summary
For an electrical connecting apparatus (1), in particular for connecting an electrical and/or electronic component (2) to a conductor substrate (3), comprising an electrically conductive contact-making element (10) and an electrical conductor (20), wherein one end (21) of the electrical conductor (20) is electrically conductively connected to the contact-making element (10), the invention proposes that the contact-making element (10) is of fork-like design with at least one first tine (11) and at least one second tine (12), wherein the first tine (11) is spaced apart from the second tine (12) by an intermediate space (13), wherein the end (21) of the electrical conductor (20) is arranged in the intermediate space (13) between the first tine (11) and the second tine (12) and is electrically conductively connected to the first tine (11) and/or the second tine (12).